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AN OVERVIEW OF THE ROLLER INDUSTRYAN OVERVIEW OF THE ROLLER INDUSTRY
Why are rollers used What is a roller Where are rollers used How are rollers manufactured Where is the roller market going
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Why Roll Coverings?Why Roll Coverings?
Virtually all industries use rollers of some type
Elastomer covered rolls provide performance factors not possible with rigid materials
Large number of polymer types and compounding ingredients allow tailoring of the roller to meet specific service requirements
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Rubber Covered Roll CompositionRubber Covered Roll Composition
Core Metal (Steel, Al, Bronze) Nonmetal (FRP)
Bonding layer Bonding agent
Cover Rubber, Polyurethane, Resin
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Polymers
Thermoset plastics Thermoplastic elastomers
Thermoplastics
Elastomers
• Phenolic or melamine resins
• epoxy and polyester resins (UP)
• etc.
• PP
• PE
• PS
• PVC
• etc.
• copolyesters
• polyether block amides
• TPU
• TPO/TPV
• SBS, SEBS
Natural rubber synthetic rubber
• SBR• NBR• EPDM• Silicone • etc.
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What is a Roll Cover?What is a Roll Cover?
Rollers are covered with elastomeric
compositions to allow the creation of a
uniform pressure area called the “NIP” “NIP” region dynamic performance must
remain constant Roller compounds must be stable over
time in the service environment
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Functions of Roller CoveringsFunctions of Roller Coverings
Feed Meter Emboss Insulate Conduct
Electricity
Drive Squeeze Stamp Isolate Dissipate
Electricity
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Roller Design FactorsRoller Design Factors
Solvents & ChemicalsTemperaturePressureRotational Speed
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Wide Range of ElastomersWide Range of Elastomers
NBR NBR/PVC XNBR HNBR EPDM CSM CR ECO
AU, EU NR SBR MQ MQ/EPDM FKM Thiokol
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Some Important Properties forSome Important Properties forRubber RollersRubber Rollers
Hardness Modulus Tear Strength Cut Resistance Compression Set Permanent Set Resilience Smooth surface
Abrasion resistance Hysteresis Chemical Resistance Ozone Resistance Heat Resistance Co-efficient of friction Non-glazing surface Good printability
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Rubber Roller DynamicsRubber Roller Dynamics - - The “NIP” areaThe “NIP” area
A
BC
D
E
HARD ROLL
ELASTOMERIC ROLL
A Entrance - compound relaxedB Entry Bulge - high extension & speedC Nip Center - high compressionD Exit Bulge - high extension & speedE Exit - compound recovered
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Roller Market SegmentationRoller Market Segmentation
4%
2%7%
9%
43%35% Graphic Arts
Pulp & Paper
Steel & Aluminum
Textiles
General Industrial
Business Machines
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Must be resistant to the
chemicals and Oils,,,
High elasticity with
abrasion resistance
Eccentrical property
during working
Changeable raw polymer
rely on changeable service
condition
Wringer rollers
Squeeze rollers
Coating rollers
Insulation rollers
Deflector rollers
Tension bridle rollers
Brake rollers
Support rollers
Steel mill Rubber RollersSteel mill Rubber Rollers
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Industrial Roller MarketsIndustrial Roller Markets
Paper industry Steel / metal
industry Furniture
Industry Wood Industry Plastic Industry
Food Industry Leather Industry Circuit Board
Industry
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Roller Manufacturing Processes Roller Manufacturing Processes SelectionSelection
Manufacturing process is selected based on:– Size of the roller
– Elastomer type
– Compound processibility characteristics
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Rubber covered rollRubber covered roll Recipe selection approach Recipe selection approach
Select a typical roll recipe and
various chemicals
List down the requirement of
properties
– Eg . least chemical affect.
Design experiments - “Ideal recipe”
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Various methods of covering rollsVarious methods of covering rolls
Casting - rollers used in Steel Mill, Pulp and Paper, and General Industrial.
Molding - small rollers used in Offset printing and Business Machines
Calender Building - medium rollers used in a majority of applications
Strip Building - rollers used in Graphic Arts, Pulp and Paper, Steel Mill, Textile and General Industrial
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Industry TrendsIndustry Trends
Increasing environmental scrutiny New equipment designs Competitive pressure has led to
evaluation of alternative production technologies
Changes in industry will demand higher performance standards, and the roller industry must keep pace with these technical advances
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SummarySummary
Hardness Hardness stability Chemical and Solvent resistance Hysteresis loss Dimension stability Permanent set
resistance
Rollers are used in nearly every industry
Rollers utilize nearly all polymer types because of the diverse applications
Successful players in the roller industry will be those who are successful communicators and are able to meet the current & future requirements, and adapt to the industry changes